Systems and methods for limiting air conditioner discharge rate

ABSTRACT

An air conditioning appliance includes a housing with a heat exchanger. A compressor is in fluid communication with the heat exchanger. The compressor is operable to circulate refrigerant through the heat exchanger. A fan is disposed within the housing. The fan is operable to flow air over the heat exchanger. A temperature sensor is disposed at an indoor portion of the housing. The controller is configured to receive a signal from the temperature sensor corresponding to a temperature measurement, and to compare the temperature measurement to a set temperature. The controller is configured to operate the fan at a first operating speed until a temperature condition is met. The controller is also configured to operate the fan at a second operating speed when the temperature condition is met.

FIELD OF THE INVENTION

The present subject matter relates generally to systems and methods for limiting the discharge rate of air conditioners.

BACKGROUND OF THE INVENTION

Air conditioners or air conditioner units are conventionally used to adjust the temperature within structures, such as dwellings and office buildings. One-unit type room air conditioners, such as single package vertical units (SPVU) or package terminal air conditioners (PTAC), are frequently used to adjust the temperature in a single room or group of rooms of a structure. Such units may be especially useful in the context of a hotel or office building where users desire control of the temperature within a specific room of a larger building structure. A typical one-unit type air conditioner or air conditioning appliance includes an indoor portion and an outdoor portion. The indoor portion generally communicates (e.g., exchanges air) with the area within a building, and the outdoor portion generally communicates (e.g., exchanges air) with the area outside a building. Generally, a fan may be operable to rotate to motivate air through the indoor portion, and another fan may be operable to rotate to motivate air through the outdoor portion. One or more control boards are typically provided to direct the operation of various elements of the particular air conditioner unit.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In one example embodiment, an air conditioning appliance includes a housing with a heat exchanger disposed within the housing. A compressor is in fluid communication with the heat exchanger. The compressor is operable to circulate refrigerant through the heat exchanger. A fan is disposed within the housing. The fan is operable to flow air over the heat exchanger. A temperature sensor is disposed at an indoor portion of the housing. A controller is in operative communication with the temperature sensor. The controller is configured to receive a signal from the temperature sensor corresponding to a temperature measurement, and to compare the temperature measurement to a set temperature. The controller is configured to operate the fan at a first operating speed until a temperature condition is met. The controller is also configured to operate the fan at a second operating speed when the temperature condition is met. The second operating speed is greater than the first operating speed.

In another example embodiment, a method of operating an air conditioning appliance includes adjusting, at a controller, an operating speed of a fan to a first operating speed. Then receiving, at the controller, a temperature measurement. Determining, at the controller, satisfaction of a temperature condition based at least in part on a difference between the temperature measurement and a set temperature. Then adjusting, at the controller, the operating speed of the fan to a second operating speed in response to the satisfaction of the temperature condition.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of an air conditioning appliance according to example embodiments of the present disclosure.

FIG. 2 provides a partially transparent elevation view of the example air conditioner unit of FIG. 1 .

FIG. 3 provides a cut-away perspective view of a housing of the example air conditioner unit of FIG. 1 , with an access door and access door frame of an access door assembly detached.

FIG. 4 illustrates a method of operating an air conditioner unit according to example embodiments of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. Furthermore, as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error.

Turning now to the figures, FIGS. 1 through 3 illustrate an example air conditioning appliance (e.g., air conditioner 100). As shown, air conditioner 100 may be provided as a one-unit type air conditioner 100, such as a single-package vertical unit. Air conditioner 100 includes a housing 114 supporting an indoor portion 112 and an outdoor portion 110. Generally, air conditioner 100 defines a vertical direction V, lateral direction L, and transverse direction T that are mutually perpendicular, e.g., such that an orthogonal coordinate system is generally defined.

In some example embodiments, housing 114 contains various components of the air conditioner 100. Housing 114 may include, for example, a rear opening 116 (e.g., with or without a grill or grate thereacross) and a front opening 118 (e.g., with or without a grill or grate thereacross) may be spaced apart from each other along the transverse direction T. The rear opening 116 may be part of the outdoor portion 110, while the front opening 118 is part of the indoor portion 112. Components of the outdoor portion 110, such as an outdoor heat exchanger 120, outdoor fan 124, and compressor 126 may be enclosed within housing 114 between front opening 118 and rear opening 116. In certain example embodiments, one or more components of outdoor portion 110 are mounted on a base pan 136, as shown.

During certain operations, air may be drawn to outdoor portion 110 through rear opening 116. Specifically, an outdoor inlet 128 defined through housing 114 may receive outdoor air motivated by outdoor fan 124. Within housing 114, the received outdoor air may be motivated through or across outdoor fan 124. Moreover, at least a portion of the outdoor air may be motivated through or across outdoor heat exchanger 120 before exiting the rear opening 116 at an outdoor outlet 130. It is noted that although outdoor inlet 128 is illustrated as being defined above outdoor outlet 130, alternative example embodiments may reverse this relative orientation (e.g., such that outdoor inlet 128 is defined below outdoor outlet 130) or provide outdoor inlet 128 beside outdoor outlet 130 in a side-by-side orientation, or another suitable discrete orientation.

As shown, indoor portion 112 may include an indoor heat exchanger 122, a blower fan 142, and a heating unit (not shown). These components may, for example, be housed behind the front opening 118. A bulkhead 134 may generally support or house various other components or portions thereof of the indoor portion 112, such as the blower fan 142. Bulkhead 134 may generally separate and define the indoor portion 112 and outdoor portion 110 within housing 114. Additionally, or alternatively, bulkhead 134 or indoor heat exchanger 122 may be mounted on base pan 136 (e.g., at a higher vertical position than outdoor heat exchanger 120).

During certain operations, air may be drawn to indoor portion 112 through front opening 118. Specifically, an indoor inlet 138 defined through housing 114 may receive indoor air motivated by blower fan 142. At least a portion of the indoor air may be motivated through or across indoor heat exchanger 122 (e.g., before passing to bulkhead 134). From blower fan 142, indoor air may be motivated (e.g., across the heating unit, which may include one or more electric or resistive heating elements) and returned to an indoor area of a room through an indoor outlet 140 defined through housing 114 (e.g., above indoor inlet 138 along the vertical direction V). Optionally, one or more conduits (not pictured) may be mounted on or downstream from indoor outlet 140 to further guide air from air conditioner 100. It is noted that although indoor outlet 140 is illustrated as generally directing air upward, it is understood that indoor outlet 140 may be defined in alternative example embodiments to direct air in any other suitable direction. A temperature sensor 200 may be mounted in indoor outlet 140 to measure the temperature of the air inside indoor outlet 140. Additional temperature sensors may be used, i.e., on heat exchanger 122, or on the exterior of air conditioner 100. The exterior temperature sensor (not shown) may measure an ambient indoor air temperature.

Outdoor and indoor heat exchanger 120, 122 may be components of a thermodynamic assembly (i.e., sealed system), which may be operated as a refrigeration assembly (and thus perform a refrigeration cycle) or, in the case of the heat pump unit embodiment, a heat pump (and thus perform a heat pump cycle). Thus, as is understood, example heat pump unit embodiments may be selectively operated perform a refrigeration cycle at certain instances (e.g., while in a cooling mode) and a heat pump cycle at other instances (e.g., while in a heating mode). By contrast, example A/C exclusive unit embodiments may be unable to perform a heat pump cycle (e.g., while in the heating mode), but still perform a refrigeration cycle (e.g., while in a cooling mode).

The sealed system may, for example, further include compressor 126 (e.g., mounted on base pan 136) and an expansion device (e.g., expansion valve or capillary tube—not shown), both of which may be in fluid communication with the heat exchangers 120, 122 to flow refrigerant therethrough, as is generally understood. The outdoor and indoor heat exchanger 120, 122 may each include coils, as illustrated, through which a refrigerant may flow for heat exchange purposes, as is generally understood.

The operation of air conditioner 100 including compressor 126 (and thus the sealed system generally), blower fan 142, outdoor fan 124, the heating unit, and other suitable components may be controlled by a control board or controller 158 (FIG. 3 ). Controller 158 may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner 100. By way of example, the controller 158 may include a memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of air conditioner 100. The memory may be a separate component from the processor or may be included onboard within the processor. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH.

Air conditioner 100 may additionally include a control panel and one or more user inputs, which may be included in control panel. The user inputs may be in communication with the controller 158. A user of the air conditioner 100 may interact with the user inputs to operate the air conditioner 100, and user commands may be transmitted between the user inputs and controller 158 to facilitate operation of the air conditioner 100 based on such user commands. A display may additionally be provided in the control panel and may be in communication with the controller 158. The display may, for example be a touchscreen or other text-readable display screen, or alternatively may simply be a light that can be activated and deactivated as required to provide an indication of, for example, an event or setting for the air conditioner 100.

FIG. 4 illustrates a method 400 for operating an air conditioning appliance, such as air conditioner 100 of FIGS. 1 through 3 . Method 400 may begin at 410 when air conditioner 100 begins either the heat pump cycle or refrigeration cycle. At 420, controller 158 may adjust blower fan 142 to a first operating speed. The first operating speed of blower fan 142 may be equivalent to a “low” fan setting. The first operating speed of blower fan 142 may be greater than zero such that the blower fan 142 flows air. Controller 158 may operate blower fan 142 at the first operating speed until, at 430, a temperature condition is satisfied. At 430, there may be numerous temperature conditions that may be satisfied. For example, the present example embodiment includes eight conditions, 431 through 438. In each condition 431 through 438, the temperature measurement may be above or below the set temperature by an offset amount, about plus or minus three degrees Celsius (3° C.).

Condition 431 may be satisfied when the temperature measurement from temperature sensor 200 is above or below the ambient indoor air temperature, depending on the type of cycle air conditioner 100 is performing. Condition 432 may be satisfied when the temperature measurement of the heat exchanger temperature is above or below the temperature measurement of the ambient indoor air temperature. Condition 433 may be satisfied when an integration of the temperature measurement from temperature sensor 200 above or below the ambient indoor air temperature with respect to time exceeds a threshold value (° C.-second). The threshold value may be a value or a plurality of values stored on controller 158. The threshold value may also be a calculation of the integral of the set temperature with respect to time. Condition 434 may be satisfied when an integration of the heat exchanger temperature above or below the ambient indoor air temperature with respect to time is above or below the threshold value. For example, condition 433 may be satisfied if the integration of temperature measurement above the ambient indoor air temperature with respect to time exceeds a threshold value (° C.-second).

At 439, four of the conditions, 435 through 438, may be governed by a set period of time. The time may be between ten seconds (10 sec) and ten minutes (10 min). Condition 435 may be satisfied when the temperature measurement from temperature sensor 200 is above or below the ambient indoor air temperature by the offset amount for the set period of time. The set period of time may correlate to a number of samples, i.e., temperature measurements, taken during the period of time. Condition 436 may be satisfied when the temperature measurement of the heat exchanger temperature is above or below the temperature measurement of the ambient indoor air temperature by the offset amount for the set period of time. Condition 437 may be satisfied when the integration of the temperature measurement above or below the temperature of the ambient indoor air temperature with respect to time exceeds the threshold value for the set period of time. Condition 438 may be satisfied when the integration of the heat exchanger temperature above or below the ambient indoor air temperature with respect to time exceeds the threshold value for the set period of time. For example, condition 437 may be satisfied if the integration of temperature measurement above the ambient indoor air temperature with respect to time exceeds a threshold value (° C.-second) for the duration of the set period of time.

When at least one of condition 431 through 438 is satisfied, the method 400 may proceed to 440. At 440, controller 158 may adjust blower fan 142 to a second operating speed. The second operating speed of blower fan 142 may be equivalent to a “normal” setting. The second operating speed may at least be greater than the first operating speed of blower fan 142. As an example, the second operating speed may be no less than twenty percent (20%) greater, no less than fifty percent (50%) greater, no less than seventy-five percent (75%) greater, no less than one hundred percent (100%) greater, no less than two hundred percent (200%) greater, no less than five hundred percent (500%) greater, etc. Accordingly, method 400 may start either the heat pump cycle or refrigeration cycle, with blower fan 142 operating at a slower speed than normal. Blower fan 142 may remain at the slow speed until a temperature condition is met. Once the temperature condition is met, blower fan 142 may operate at a speed that is faster than the slow speed or considered the normal speed. One skilled in the art would understand that method 400 may be applied to any air conditioner appliance, and air conditioner 100 is provided by way of example and is not intended to be limiting.

As may be seen above, when air conditioner 100 enters a cooling or heating cycle, controller 158 may operate the blower fan 142 at the first, slower, low speed. The controller then monitors the indoor ambient temperature and temperature inside of air conditioner 100, waiting for a temperature condition to be met. Blower fan 142 may remain at the slow speed until at least one of the temperature conditions is met. Once the temperature condition is met controller 158 may adjust blower fan 142 to a second, faster, normal speed.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

1. An air conditioning appliance, comprising: a housing; a heat exchanger disposed within the housing; a compressor in fluid communication with the heat exchanger, the compressor operable to circulate refrigerant through the heat exchanger; a fan disposed within the housing, the fan operable to flow air over the heat exchanger; a plurality of temperature sensors, each one of the plurality of temperature sensors operable to measure a respective one of an external air temperature, an ambient indoor air temperature, and an indoor outlet air temperature; and a controller in operative communication with the temperature sensor, the controller configured to receive a signal from the temperature sensor corresponding to a temperature measurement and to compare the temperature measurement to a set temperature, wherein when the air conditioner appliance begins one of a heat pump cycle or a refrigeration cycle, the controller configured to operate the fan at a first operating speed until a temperature condition is met, the controller configured to operate the fan at a second operating speed when the temperature condition is met, the second operating speed being greater than the first operating speed.
 2. (canceled)
 3. The air conditioning appliance of claim 1, wherein the temperature condition comprises the temperature measurement above or below the ambient indoor air temperature by an offset amount.
 4. The air conditioning appliance of claim 3, wherein the temperature condition further comprises the temperature measurement above or below the ambient indoor air temperature by the offset amount for a set period of time.
 5. The air conditioning appliance of claim 1, wherein the temperature condition comprises the temperature measurement of the heat exchanger temperature above or below the temperature measurement of the ambient indoor air temperature by an offset amount.
 6. The air conditioning appliance of claim 5, wherein the temperature condition further comprises the temperature measurement of the heat exchanger temperature above or below the temperature measurement of the ambient indoor air temperature by the offset amount for a set period of time.
 7. The air conditioning appliance of claim 1, wherein the temperature condition comprises an integration of the temperature measurement above or below the ambient indoor air temperature over time is above or below a threshold value.
 8. The air conditioning appliance of claim 7, wherein the temperature condition further comprises the integration of the temperature measurement above or below the temperature of the ambient indoor air temperature over time is above or below the threshold value for a set period of time.
 9. The air conditioning appliance of claim 1, wherein the temperature condition comprises an integration of the heat exchanger temperature above or below the ambient indoor air temperature over time is above or below a threshold value.
 10. The air conditioning appliance of claim 9, wherein the temperature condition further comprises the integration of the heat exchanger temperature above or below the ambient indoor air temperature over time being above or below the threshold value for a set period of time.
 11. A method of operating an air conditioning appliance, comprising: adjusting, at a controller, an operating speed of a fan to a first operating speed. receiving, at the controller, a temperature measurement; determining, at the controller, satisfaction of a temperature condition based at least in part on a difference between the temperature measurement and a set temperature, the temperature condition comprising an indoor ambient air temperature; adjusting, at the controller, the operating speed of the fan to a second operating speed in response to the satisfaction of the temperature condition, wherein adjusting the operating speed of the fan to the first operating speed occurs when the air conditioner appliance begins one of a heat pump cycle or a refrigeration cycle.
 12. The method of claim 11, wherein the first operating speed of the fan is less than the second operating speed, and the fan remains at the first operating speed until the temperature condition is satisfied.
 13. The method of claim 12, wherein the temperature condition comprises the temperature measurement above or below the ambient indoor air temperature by an offset amount.
 14. The method of claim 13, wherein the temperature condition further comprises the temperature measurement above or below the ambient indoor air temperature by the offset amount for a set period of time.
 15. The method of claim 12, wherein the temperature condition comprises the temperature measurement of a heat exchanger temperature above or below the temperature measurement of the ambient indoor air temperature by an offset amount.
 16. The method of claim 15, wherein the temperature condition further comprises the temperature measurement of the heat exchanger temperature above or below the temperature measurement of the ambient indoor air temperature by the offset amount for a set period of time.
 17. The method of claim 12, wherein the temperature condition comprises an integration of the temperature measurement above or below the ambient indoor air temperature over time is above or below a threshold value.
 18. The method of claim 17, wherein the temperature condition further comprises the integration of the temperature measurement above or below the temperature of the ambient indoor air temperature over time is above or below the threshold value for a set period of time.
 19. The method of claim 12, wherein the temperature condition comprises an integration of the heat exchanger temperature above or below the ambient indoor air temperature over time is above or below a threshold value.
 20. The method of claim 19, wherein the temperature condition further comprises the integration of the heat exchanger temperature above or below the ambient indoor air temperature over time being above or below the threshold value for a set period of time. 